Auxiliary tank fitting - alternatives to buulkhead?

[Specter]

I'm planning to add an aux fuel tank to my '05 FJR, and the only reference I find is to drill and add a bulkhead fitting to the tank. I would like to avoid a permanent modification.

What other options are there? Sampson offers a no-hole kit with pump, etc. Has anyone used that, and what does it tap into?

 

[SkooterG]

Dude, youse gots to drill a hole.

I know of ***ZERO*** fuel cell applications on an FJR that didn't connect via a bulkhead fitting on the bottom of the main fuel tank.

If it bugs you that much, you can do what others have done and buy an extra tank off ebay for your drilling.

 

[user 213]

I run a fuel cell, and did install a bulkhead fitting.

So, why are you squeamish about drilling the hole? It's not that big a deal. It has no impact on resale. All you have to do is tuck the hose away with the drybreak fitting and inform the next owner that it's there.

The only alternative I've read about involved a Gen II bike and disassembly of the fuel pump, fabrication of a new plastic fitting to replace a blank on the Gen II pump that is used on the Gen I for fuel return. You can't tap into the fuel lines easily due to pressures involved as I understand. It would tend to back feed to the Aux tank instead of draw from it.

I've not seen or heard of any "no hole" kits from Sampson or anyone else. They say "Or if you really, really won't install the bulkhead fitting; we can provide a pump, switch and parts to make it work without drilling "the hole" at additional cost." but make no mention of how that's done, or if anyone has tested it yet.

 

[TruWrecks]

Find a shop that know how to weld on fuel tanks. Take the tank to them and ask the shop to drill and weld a bung fitting so you can thread in a fitting for the hose. If you want it removed you can put a plug in it.

 

[Joe2Lmaker]

The only alternative I've read about involved a Gen II bike and disassembly of the fuel pump, fabrication of a new plastic fitting to replace a blank on the Gen II pump that is used on the Gen I for fuel return.

If you go to my member profile, there is a link to the full write-up on my 'About Me' page.

 

[madmike2]

I would think the only way a "No Hole" system will work is a to have a pump and hose that you can transfer the gasoline via the filler cap on the top. In other words, pull over, unroll the hose and open the gas tank, turn on the pump and transfer the fuel.

Easy-peasy....no hole in your tank, no ability to transfer fuel "on-the-move".

Because the FJR is fuel injected all of the hoses on the bottom of the tank are pressurized by the fuel puump. There is no way to "T" into them and transfer fuel from an auxiliary tank. To transfer via gravity or on-the-move from Sampson's tail-dragger tank" you must use a bulkhead fitting. OR....do as Jo2lmaker did.

It all depends on what your desires/needs/abilities are.

 

[Specter]

So, why are you squeamish about drilling the hole? It's not that big a deal. It has no impact on resale. All you have to do is tuck the hose away with the drybreak fitting and inform the next owner that it's there.

I replaced my tank last month - it costs almost $800 with emblems and heat shields - so I'm hesitant to poke holes in it If I do decide to drill it, at least I have one to practice on

I've not seen or heard of any "no hole" kits from Sampson or anyone else. They say "Or if you really, really won't install the bulkhead fitting; we can provide a pump, switch and parts to make it work without drilling "the hole" at additional cost." but make no mention of how that's done, or if anyone has tested it yet.

I wrote to Sampson for an explanation. I'll post their reply. I think they tap into the fuel return line. The kit has an electric fuel pump and valve. It probably overcomes the return line pressure and pumps aux tank fuel into the main.

 

[user 213]

Use a Uni-bit to drill the tank. They are specifically designed to drill clean holes in thin metal.

Another potential point - Folks sometimes sell the tank with the bulkhead fitting w/part trade for a virgin tank when they sell the bike.

Used '05 tanks are pretty easy to come by. That color crashes a lot.

 

[FJRay]

Turbo Dave has a spare tank with the fitting in it. I don't think he sold it yet.

 

[kaitsdad]

So, why are you squeamish about drilling the hole? It's not that big a deal. It has no impact on resale. All you have to do is tuck the hose away with the drybreak fitting and inform the next owner that it's there.

I replaced my tank last month - it costs almost $800 with emblems and heat shields - so I'm hesitant to poke holes in it If I do decide to drill it, at least I have one to practice on

I've not seen or heard of any "no hole" kits from Sampson or anyone else. They say "Or if you really, really won't install the bulkhead fitting; we can provide a pump, switch and parts to make it work without drilling "the hole" at additional cost." but make no mention of how that's done, or if anyone has tested it yet.

I wrote to Sampson for an explanation. I'll post their reply. I think they tap into the fuel return line. The kit has an electric fuel pump and valve. It probably overcomes the return line pressure and pumps aux tank fuel into the main.

Sampson provides a kit that will allow you to tap into the fuel return line of some bikes, but it is NOT compatible with FJR's, of any year. The FJR uses a very high pressure fuel pump to maintain injection pressure at all times - and attempting to tap into the return line on the GenI's or the supply line on the GenII will only result in a very bad and $$$ situation.

You will need to install a bulkhead fitting in your tank to utilize any style of aux fuel supply.

It's not hard to do - just do your homework from the posts of those that have gone before you, and then do it. No biggie.

 

[Specter]

So, why are you squeamish about drilling the hole? It's not that big a deal. It has no impact on resale. All you have to do is tuck the hose away with the drybreak fitting and inform the next owner that it's there.

I replaced my tank last month - it costs almost $800 with emblems and heat shields - so I'm hesitant to poke holes in it If I do decide to drill it, at least I have one to practice on

I've not seen or heard of any "no hole" kits from Sampson or anyone else. They say "Or if you really, really won't install the bulkhead fitting; we can provide a pump, switch and parts to make it work without drilling "the hole" at additional cost." but make no mention of how that's done, or if anyone has tested it yet.

I wrote to Sampson for an explanation. I'll post their reply. I think they tap into the fuel return line. The kit has an electric fuel pump and valve. It probably overcomes the return line pressure and pumps aux tank fuel into the main.

Sampson provides a kit that will allow you to tap into the fuel return line of some bikes, but it is NOT compatible with FJR's, of any year. The FJR uses a very high pressure fuel pump to maintain injection pressure at all times - and attempting to tap into the return line on the GenI's or the supply line on the GenII will only result in a very bad and $$$ situation.

You will need to install a bulkhead fitting in your tank to utilize any style of aux fuel supply.

It's not hard to do - just do your homework from the posts of those that have gone before you, and then do it. No biggie.

I guess I'll get to work fabricating the tank mount, etc., then bite the bullet and fire up the uni-bit.

 

[James]

I guess I'll get to work fabricating the tank mount, etc., then bite the bullet and fire up the uni-bit.

It really isn't that bad. I got my fuel cell from someone who wouldn't drill the hole . My bike is my main transportation, and was easily able to start & finish in a couple of hours. Read the directions, make sure you have everything you need, and drill the hole.